Rebuild progress all in one thread

Build and Restoration Threads Belong Here

Moderators: Cal_Gary, T. Highway, Monkey Man, robi

Josh
SFC
SFC
Posts: 702
Joined: Tue Nov 06, 2007 9:02 pm

Re: Rebuild progress, Thread #2 (3/2/10) PG 7

Post by Josh »

thanks guys!

Time for an update... been busy, just havent been posting. Here is how she sits now... the raditor will get painted flat black...

Image

Image

got the front winch wired up. Mounted the solenoids to the original crossmember in the front. Well protected, and, easy to get to if I need to change one. I got the aluminum plate I needed to finish the modifications to the original case, but, have been holding off on bolting them on until I finished the radiator mounts.

Image

Image

Image

I had to modify the clutch handle for the winch as well. Because I am mounting the old case halves over the new winch to make the new one look like the original, I won't be able to get to it, so I made an extension, and passed it through the frame, behind the bumper, so that it is easy to get to.

Image

Speaking of radiator mounts... I got those done as well. Super easy. LOVE that flex-A_lite radiator. The rails on the sides of it make it so easy to mount it. I bent up some "Z" bent brackets that will bolt to the original radiator mount points. Waiting to install it until the crank position sensor (CPS) is finished, which, I also got done, just tonight.

The CPS was a royal bitch. Murphy's law fought me the whole way. The CPS is the main sensor the EFI needs to run, all the injection, timing, and other functions are mainly derived from what it tells the ECU, so, it is very important that it be rigidly mounted, and accurately spaced and located.

I had the original crank pulley OD turned some time ago so that it was a medium press fit to push the Ford escort 36-1 timing wheel onto it. They happened to almost be the same diameter, so, that part was easy. The hard part was the crank sensor mounting bracket. It needs both radial and degree adjustment, so it must be slotted. The diameter of the escort wheel also happens to be almost exactly the same diameter as the harmonic balancer, and, the offset of the factory pulley happens to be almost exactly the same as the depth of the sensor and bracket, so, it made building the bracket a challenge.

Ideally, I would just have a plate behind the bracket, pass bolts through the sensor, through the mounting bracket slot, and tighten them down and be done, BUT, with the harmonic balancer's OD being EXACTLY the same as the ID of the sensor slot, that idea went out the window, as the plate behind the bracket would hit the harmonic balancer.

So, after some brainstorming, I came up with the "C" clip idea... Bolts pass through the sensor, through the clip, through the mounting slot, and back through the clip, and bolt to the back of it, so, it clamps down on the bracket, without needing to come anywhere near the harmonic balancer... Works awesome! I clamped it down tight, and tried to pry it ou of position with a screwdriver and couldnt budge it.

Image

Image

Image

The main bracket is held to the block with two pieces of 3/8" all thread. I welded stop nuts where it hits the block (original bolts held the timing set cover down), and where the bracket threads on so that the bracket doesnt move or loosen up over time.

Image

Image

Image

Image

I also got the intake manifold on, bolted the fuel rails down, and all that jazz. I jsut have to make an Idle air Control valve block. The IAC controls the idle speed, and is what speeds up and slows down your idle when the car is cold and warming up. I could buy a block online, but, $70 for a hunk of aluminum with a few holes in it seems rediculous so, I'll make my own.

Image

Once that's done, I need to do some work to the power steering system (didn't ensue proper clearances on a few things... D'oH!!!), install everything I just mentioned above, get som fluids in it, finish the wiring, and, we can light the beast!!!
Image
Josh
SFC
SFC
Posts: 702
Joined: Tue Nov 06, 2007 9:02 pm

Re: Rebuild progress, Thread #2 (3/2/10) PG 7

Post by Josh »

windshield frame and doors are on. Friggin cab is bent like 1/2"!! Went to close the doors and nowhere close to fitting. had to "adjust" the hinges in the front with my 3 lb mallet, which, of course screwed up the paint, so, gotta touch that up. Luckily it is on the back side of the hinge, so it won't be too obvious. Still pissed me off though! :evil:

Image

Image
Image
Josh
SFC
SFC
Posts: 702
Joined: Tue Nov 06, 2007 9:02 pm

Re: Rebuild progress, Thread #2 (3/2/10) PG 7

Post by Josh »

Got the CPS mounted and aligned. Also got the radiator in, the brackets I cooked up for it worked out great. Got the radiator expansion tank in, and the winch covers half mounted. LOVE that Flex-A-Lite radiator. the slotted mounts on the tanks make it so easy to mount, and it fits the truck perfectly!

Also got the rear winch half wired as well. Great progress tonight:

Image

Image

Image

Image
Image
JGPierce
PVT
PVT
Posts: 39
Joined: Fri Oct 19, 2007 8:45 pm
Location: Seacoast, New Hampshire

Re: Rebuild progress, Thread #2 (3/2/10) PG 7

Post by JGPierce »

Looks great.

Which radiator (part #) did you go with?

Thanks.

John
Josh
SFC
SFC
Posts: 702
Joined: Tue Nov 06, 2007 9:02 pm

Re: Rebuild progress, Thread #2 (3/2/10) PG 7

Post by Josh »

http://www.jegs.com/i/Flex-a-lite/400/51118L/10002/-1

Flex-A-Lite model 51118L. Came with the fan and the shrouding. Made in the USA.
Image
Josh
SFC
SFC
Posts: 702
Joined: Tue Nov 06, 2007 9:02 pm

Re: Rebuild progress, Thread #2 (3/2/10) PG 7

Post by Josh »

more work done... 22 hous of wiring. EFI is done, haven't powered it up yet, as I still need to finish the main power cables. Got the IAC motor mounted, making the block to hold it wasn't bad at all, and certainly not worth the $75 for one online. got the winch cases mounted in the front, looks good! Also got the power steerig lines done, all I need to do is make a reservoir to sit on the drivers fender up by the cab. The one I nabbed from the boneyard isn't going to work without some serious modification, and, if I have to do that much work, I'll just make a new one that fits exactly how I want it. Driver's side fender is also on, but, not in the pictures.

IAC block, wiring mess half done. looks much much better now, I need to toake another shot of it:

Image

Image

Image

tailights mounted as well... a bit lower than I originally intended...will probably go back later and move them up some:

Image

Image

hydro assist ram lines:

Image

Image

feed in line is ultra short:

Image

winch cases. you can see the plates I made for the inside of each case. countersunk the heads so they look factory to anyone that doesnt know any better. Clear coated them with 3 coats of clear as well so they stay pretty:

Image

Image

looks dumb without the drivers fender... it's on now, but, you get the idea:

Image

Image
Image
Josh
SFC
SFC
Posts: 702
Joined: Tue Nov 06, 2007 9:02 pm

Re: Rebuild progress, Thread #2 (3/2/10) PG 7

Post by Josh »

Got the power steering tank made tonight. Fits the truck perfectly, which it should, since it is hand made from flat steel. The tube out the bottom is the feed to the pump, while the fitting in the nose is the return back from the box. Holds just over a gallon of fluid.

Image

Image

Image

Image

Image

Image

Image

Image
Image
Rich
CPL
CPL
Posts: 107
Joined: Sat Oct 20, 2007 5:49 pm
Location: Asheboro NC

Re: Rebuild progress, Thread #2 (3/2/10) PG 7

Post by Rich »

Josh,
Excellent job!!! It is looking Great!!!
Rich Szklany
User avatar
HingsingM37
1SG
1SG
Posts: 1447
Joined: Sat Oct 20, 2007 3:43 am
Location: North Carolina

Re: Rebuild progress, Thread #2 (3/2/10) PG 7

Post by HingsingM37 »

Josh, You're a maniac! :o Everything is looking fantastic and you should be proud of your talent :mrgreen: I want to here an audio file or see some video when your fire that monster up 8)
David
HingsingM37
1958 M37B1
1968 M101A1 Trailer
MVPA# 33078

"Do Not Take Counsel of Your Fears"
General George S. Patton Jr.

"Those who pound their guns into plows, will plow for those who do not".
Josh
SFC
SFC
Posts: 702
Joined: Tue Nov 06, 2007 9:02 pm

Re: Rebuild progress, Thread #2 (3/2/10) PG 7

Post by Josh »

well, good, and bad news.

Good news is, all of the electrical works, except two things: the turn signals, and, the CPS.

I think the turn signals are the flasher module, it didnt have any plug markings, so, I just took a guess.

The CPS of course is the main sensor for the EFI, so, everything else on the EFI is working but that, and, unfortunately, that controls the ignition and injection timing, so, it won't light.

I have a few ideas though. Either A. my ground isnt any good B. the sensor is bad (very possible, got it from the junkyard) or, C. I have the + and - wires backwards.

So, I have a few things to try tomorrow. I am willing to bet the + and - wires are backwards, which wouldn't give me any signal at all, just like I am seeing. of course, the other two would react the same, but, The ground should be good (grounded it right to the EFI case, and everything else on it is working fine), and, CPS sensors don't go bad that often.

Everything else electrically works though, headlights, taillights, running lights, winches, brake lights, widebands! not bad!

on a funny side note:

Got the starting circuit done first, cranked it, worked fine the first try. Checked oil pressure. nothing. Tried again for a few seconds, still nothing. At that point, I didn't want to crank any more without oil pressure, so, I pulled the dizzy and made a tool to spin the pump with, an I was spinning it for bout 45 seconds, full blast and getting nothing... getting VERY pissed off, then, I realized... I was going clockwise. Dizzy in the big blocks spin counterclockwise. D'oH :mrgreen: built pressure in about 5 seconds after I started turning it the right way!
Image
M37UK
SSGT
SSGT
Posts: 460
Joined: Fri Oct 24, 2008 12:38 pm
Location: Aberdeenshire, Scotland

Re: Rebuild progress, Thread #2 (3/2/10) PG 7

Post by M37UK »

Jeez Josh, imagine not realising about the Dizzy spinning counterclockwise in the big blocks............... :wink:

Almost lift-off time eh?
Stu

1952 Dodge M37 with 1952 M101 Trailer
MVT UK
SMVG Scotland
Josh
SFC
SFC
Posts: 702
Joined: Tue Nov 06, 2007 9:02 pm

Re: Rebuild progress, Thread #2 (3/2/10) PG 7

Post by Josh »

we've got RPM input. There are some pins on the ECU board that have jumpers on them, ad they were not jumpered right. I moved the jumpers to the right spot, and we got a noisy signal, so I adjusted the crank position hysteresis and noise circuits, and now have a nice, clean signal. the missing tooth is pinging about 3X higher than the rest, and the rest have a nice smooth wave motion to them with engine cranking RPM.

It still wont light, it sputters and burps up the intake manifold, but, won't go. I pulled a plug to check spark, and it blew a TON of fuel out the plug hole, so, I need to make some adjustments to the fuel curves. My widebands are pegged out full rich, <10:1 AFRs, so it needs som trimming, and it will probably light.
Image
k8icu
1SG
1SG
Posts: 1261
Joined: Fri May 23, 2008 5:23 am
Location: Cleveland Ohio
Contact:

Re: Rebuild progress, Thread #2 (3/2/10) PG 7

Post by k8icu »

Sounds like it's flooding out, but if it's burping throught the intake then you may still have a timing issue. Are you running a distributor or a coil pack? If distributor is it in correct? Coil pack in right order?
M37s are HMMWV in my world!
Josh
SFC
SFC
Posts: 702
Joined: Tue Nov 06, 2007 9:02 pm

Re: Rebuild progress, Thread #2 (3/2/10) PG 7

Post by Josh »

Done with the truck till spring, if ever again.

Something's wrong with the fuel system, drained the oil and there was 3 1/2 quarts of gas in it. I know for sure that all the misfired have blown an exhaust manifold gasket, and probably a headgasket while trying to sort out the crank position sensor issues, and, with that much gas in the oil, probably spun the bearings in the bottom end too.

I'm just tired of it.
Image
Master Yota
MSGT
MSGT
Posts: 828
Joined: Sun Nov 15, 2009 11:50 am
Location: Prince George BC Canada
Contact:

Re: Rebuild progress, Thread #2 (3/2/10) PG 7

Post by Master Yota »

I seem to recall similar feelings when a hood was dropped. You'll pull through, and you'll figure it out. WE have faith.

I also recall you saying there was a reason for using a cheap engine to try this on. Why bother blowing up a 5k engine, when you can blow up a 500.00 dollar engine?

I'll readily admit, I know nothing about fuel injection, and even less about turbo's, when compared to your wisdom and experience. But I am an engineer, and I've got some experience with trouble shooting:

Your bearings will probably be ok, as oil is heavier than gas. So long as the oil pickup was submerged in the pan, the pump should have lubed the bearings at least as fast as the gasoline was washing it out. Don't assume anything untill you've dropped the pan and had a look. I hope for your sake that you'll be pleasantly surprised.
3.5 quarts of gas in the bottom end sounds like a classic case of flooding (Thats me - captain obvious :mrgreen: ) I can think of a few trouble points, fuel pressure too high, injector pulse too long, injectors too big, irregular or weak spark. You've got a far superior grasp of the technical end, but hopefully this will jog your memory, or least make the light bulb flash... :idea:

BTW - you won't be happy with a 4bt. Look how nuts you went with a big block!

We as engineers are not usually satisfied with a happy ending. The craving for an answer to a problem is what drives us. We are not measured by our sucess's or failures, but by our tenacity at finding the impossible solution.
Ray
1953 CDN. M37
1954 CDN. M152
Post Reply